Method of Surfacing a Substrate

ABSTRACT

A method is provided of resurfacing a substrate with a natural stone the substrate having a top surface and an edge, the method including placing a plurality of templating strips on the top surface to form a template defining an outside dimension, cutting out a top piece for resurfacing the top surface based on the outside dimension of the template, cutting out an edge band for resurfacing the edge of the substrate, bonding the edge band and the top piece together to form a replacement top and adhesively joining the replacement top to the substrate. A plurality of templating jigs may be used for forming a template. Pieces of natural stone may have respective bevel cuts made in their respective edges for adjoining with other pieces to form a replacement top of natural stone. Inside edges may be reinforced with a fiberglass cloth coated with a polyester resin. A plurality of natural stone pieces may be adjoined to form a segmented radius of curvature for covering a corresponding radius of curvature of an edge of the existing substrate.

RELATED APPLICATION

This application is a continuation of prior application Ser. No.10/977,056, filed Oct. 29, 2004, which claims the benefit of U.S.Provisional Application No. 60/540,455 filed Jan. 30, 2004, both ofwhich are specifically incorporated herein by reference.

BACKGROUND OF THE INVENTION

This invention relates in general to fabricating material used forutilitarian and decorative surfaces and in particular to a method offabricating slabs of natural stone for resurfacing existing structuresor surfacing new construction.

Granite is used in many different applications such as fireplacesurrounds, shower walls, columns, flooring and countertops. Naturalstone granite and marble are typically cut in slabs that areapproximately two to three centimeters thick. Such slabs havetraditionally been fabricated by cutting and shaping into appropriatesizes at this thickness to form new or replacement countertops.

Three areas of concern with respect to using traditional granite forcountertop replacement are: 1) inconvenience to the customer, 2) turnaround time to complete the job and 3) countertop removal. Replacingcountertops is difficult, time consuming and potentially stressful forthe customer. It typically requires more than one skilled trade tocomplete installation and quite often causes collateral damage tosurrounding surfaces that have to be repaired at the customer's expense.It frequently takes upwards of eight to ten weeks or longer forcountertops to be replaced using traditional processes and materials.

SUMMARY OF THE INVENTION

Technology has been developed to cut natural stone slabs thinner thanthe traditional two to three centimeter thick slabs. This was done toincrease the yield of the blocks from which the slabs are cut. The newthickness varies from about five millimeters to about two centimeters.Processing or fabricating natural stone this thin has proved to bedifficult due to full slabs breaking or developing unacceptablecracking.

The inventor of the present invention has determined that using existingcountertops for resurfacing instead of newly constructed woodedsubstrates allows for improved efficiencies in templating, fabricating,preparing and installing the countertops. This may result in cost andtime savings to the customer while providing the lustrous appearance ofa solid granite countertop of traditional thickness.

Certain fabrication techniques may use a wooden build up or frame tosupport stone surfaces that are thinner than traditional stonethicknesses. Such methods typically replace existing countertops usingthinner slabs in the same manner as if slabs of conventional thicknesswere being used. The existing countertops are removed, which risksdamage to the underlying frame and ancillary structure, and the newcountertops having an underlying frame are installed. In this respect,the processes using thinner natural stone product are really nodifferent nor do they offer any measurable advantages over traditionalthicknesses of the natural stone product.

One aspect of the present invention allows for resurfacing existingcountertops or other suitable surfaces with a resurfacing material suchas a natural stone, including granite and marble, for example. Anexemplary embodiment allows for using granite slabs of less thanapproximately two centimeters in thickness with or without a reinforcedbacking. It will be appreciated that natural stone of granite andmarble, for example, having other dimensions may be used for resurfacingapplications in accordance with aspects of the invention.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of an exemplary templating fixture orjig used in accordance with aspects of the invention.

FIG. 2 is a plan view of exemplary templating strips laid out on amaterial for surfacing a substrate.

FIG. 3 is a plan view of exemplary templates laid out on a material forsurfacing a substrate.

FIG. 4 is an end view of an edge formed in accordance with aspects ofthe invention.

FIG. 4A illustrates a relationship between an edge band and a countertopfor sizing the edge band.

FIG. 5 is a broken view of two exemplary pieces of material to beadjoined in accordance with aspects of the invention.

FIG. 6 is an end view of the pieces of FIG. 5 assembled to form an edge.

FIG. 7 is an end view of the assembly of FIG. 6.

FIG. 8 is an end view of the assembly of FIG. 6.

FIG. 9 is a perspective view of an edge band prepared with a radius ofcurvature in accordance with aspects of the invention.

FIG. 10 is a partial cross-sectional view of an exemplary replacementtop installed in a typical countertop arrangement.

DETAILED DESCRIPTION OF THE INVENTION

Resurfacing an existing countertop in accordance with aspects of theinvention may include the step of templating or making templates of theexisting countertop. Aspects of the invention may be used forresurfacing various surfaces or used with other substrates such asbuilding original countertops. Slabs of natural stone, such as graniteranging in thickness from about 5 millimeters to about 2 centimeters maybe used in accordance with embodiments of the invention. The personmaking the templates may make notes on the templates that provideinstructions or guides to other persons involved in the resurfacingprocess including acceptable ranges of tolerance to ensure a proper fitwhen the fabricated stone is installed.

FIG. 1 illustrates a partial cross sectional view of a cabinet frame 12,an existing countertop 14, a Luan strip 16 and an exemplary embodimentof a templating fixture or jig 18. Jig 18 may be used as a means fordetermining an outside dimension of a replacement piece of stone such asa piece for resurfacing countertop 14. Alternate means may be used orthe outside dimension may be estimated based on the actual measurementsof countertop 14; however, this may not be as accurate as dimensionsdetermined using jig 18. A wing nut 20 may be used for clamping jig 18to countertop 14. Jig 18 may be made of various materials such as wood,aluminum or lightweight steel, for instance. Jig 18 may be fabricated indifferent sizes depending on the dimensions of the substrate beingresurfaced, the amount of overhang desired for the material used forresurfacing the substrate and/or the dimension of substrate edges beingresurfaced. Various materials may be used for templating such as ⅛ Luancut into various sized strips. One or more spaced apart jigs 18 may befastened at various points to the outer edges of countertop 14 asfurther shown in FIG. 2. The number of jigs 18 used may depend in parton the length of a countertop 14 edge and/or the area to be resurfaced.Jigs 18 may be sized to accommodate the dimensions of the granite orother material to be installed.

For example, a gap or spacing 22 may be formed in jig 18 to templatethat portion of granite that will extend beyond or overhang the edge ofa top surface 17 of countertop 14 as shown in FIG. 1. In this respect,with jig 18 secured to countertop 14, an end portion 15 of Luan strip 16extends beyond or overhangs the edge of top surface 17 and abuts anupper flange 24 of jig 18. The end portion 15 simulates the amount ofgranite surface that will extend or overhang beyond the edge of topsurface 17 when the granite surface is installed. In this aspect, adistance, equal to space 22, from the edge of top surface 17 to upperflange 24 may equal a width of a piece of granite that will cover thefront edge of top surface 17. This allows for the overhanging portion tojoin with another piece of granite that fits along the front edge ofcountertop 14 as more fully described herein. In an embodiment thisdistance may be about 5 millimeters to about 10 millimeters, which wouldbe the thickness of a granite surface covering top surface 17.

The amount of end portion 15 overhanging top surface 17 may be the samelength as the width of space 22, which may be the same dimension as thethickness of the granite being used. Jig 18 may comprise an interiorplate 19 that fits flush against the front edge of countertop 14 whenfastened in place. An exterior plate 21 may be connected with theinterior plate 19 by a top guide plate 23 and a lower guide plate 25.Space 22 may be formed between plates 19, 21 and may be approximatelyequal to the thickness of granite being installed. Jig 18 may befastened to countertop 14 by sliding plates 23, 25 over the front edgeof countertop 14 and tightening wing nut 20 making sure that plate 19 issnug or flush against the front or old edge.

Referring to FIG. 2, a plurality of Luan strips 16 may be laid flat fortemplating the surface of countertop 14. Strips 16 may be laid to abutrespective flanges 24 of jigs 18 along the edges of countertop 14 andagainst all existing walls, back splashes 30 or other structuresadjacent countertop 14. The ends of strips 16 may be overlapped so theymay be glued together to form a respective template 40 shown in FIG. 3.Prior to gluing, all strips 16 should be snug against respective flanges24 of jigs 18 and other walls or objects bordering the resurfaced topsuch as back splash 30 to ensure accuracy. Once strips 16 are in placeat least some or all of their respective ends may be glued together tostabilize the template. Alternate methods may be used for templating ordetermining the dimensions of countertop 14 or other surfaces so thatpieces may be cut for resurfacing.

Embodiments of the invention allow for gap or spacing 22 to serve as anexpansion gap to accommodate the non-calibrated thickness of resurfacingmaterial, such as natural stone that may vary in thickness ±4 mm, forexample. In this aspect, a substrate surface replacement piece may besized to include an expansion gap, such as gap or space 22 to allow forthe expansion and contraction of dissimilar materials. As shown in FIG.2, Luan strips 16 may be placed on top surface 17 so that an outsidedimension of the Luan strips 16 is substantially the same as that of topsurface 17. A replacement piece may then be sized based on this outsidedimension plus the width of expansion gap 22. This allows for theexpansion gap 22 to be sized slightly larger than a maximum thickness ofthe resurfacing material, which may vary in thickness along the lengthsor its lateral edges. Alternatively, other methods may be used, such asdigitized or electronic templates, for determining the width of theexpansion gap 22 and/or overall dimensions of a replacement piece forresurfacing top surface 17 and/or edge 19.

Templates should be sized within an acceptable range of tolerance sothat when removed they are substantially identical to the countertop 14to which they were formed. In certain areas there may be no countertop14 edge due to limited space, such as where a household range ispositioned with respect to the existing countertop. In this respect, thetemplate may be extended to within about 1/16″ of the range so that theedge of countertop 14 parallel to the side of the range won't be visiblethrough a gap when the granite is in place.

Referring to FIG. 3, after sizing and forming exemplary templates 40they may be appropriately labeled or identified to associate a template40 with an area of countertop 14 to be resurfaced and for which a pieceof granite will be sized and cut. Digital pictures of existingcountertops 14 with and without templates 40 on them provide fabricatorswith another source of information as well as documenting work forfuture reference. Information specific to a countertop 14 beingresurfaced may be included or noted on appropriate templates 40 duringthe step of templating. For example, finished edge locations, existingedge thickness, wall location and back splash locations, back splashheight and depth, range, refrigerator location, sink center and/or cooktop locations, seam locations and tabs may be noted on respectivetemplates 40 for use by a fabricator.

It will be appreciated that aspects of the present invention may be usedwith natural stone, such as granite and marble of varying thicknesses,or other materials having similar physical characteristics orproperties. Some stones, such as a slab of granite come with an attachedbacking material from the factory to stabilize the stone. Aspects of thepresent invention may be used with such a backing in place withoutcompromising the integrity of the finished surfaces to be installed.

Referring to FIG. 3, a step of the present invention allows fortemplates 40 to be laid out on a slab or sheet of stone 44, such as agranite slab having a thickness of between about 5 millimeters and 2centimeters, in such a manner as to best utilize the entire sheet 44. Aswill be appreciated, templates 40 provide a representation of arespective surface area of countertop 14 to be resurfaced plus an amountof slab 44 that will extend beyond or overhang an edge of countertop 14as best shown in FIG. 1. This amount is approximately equal to gap orspacing 22 formed by jig 18.

A step allows for calculating an amount or dimension of material fromslab 44 that will be used to cover an edge of countertop 14, such as afront or side edge against which respective interior plates 19 of jigs18 abut when secured to countertop 14. Other surfaces to be resurfacedsuch as the front surface and top edge of back splash 30 may be cut fromslab 44. A grease pencil or other appropriate marker may be used totrace templates 40 out on slab 44 and transfer any notes from arespective template 40 onto the associated piece of slab 44 to becutout.

Pieces of slab 44 cut from respective templates 40 may be cut withcertain edges forming a right angle with respect to a surface of slab44. This allows for those edges to abut or fit substantially flushagainst another surface such as a wall or backsplash 30 not beingresurfaced. Other edge portions of a piece of slab 44 may be a miter orbevel cut such as those portions that will be joined with another miteror bevel cut to form a 90° edge or angle such as when resurfacing backsplash 30.

For example, FIG. 4 illustrates a top surface 50 of a piece cut fromslab 44 and a front edge 52 of a piece cut from slab 44 that abut toform an approximately 90° edge. This edge may fit over a corresponding90° edge surface formed between top surface 17 and the front edge ofcountertop 14, which is the edge against which interior plate 19 isflush against in FIG. 1. In an embodiment, bevel cuts 56 may be made inthe adjoining ends of pieces 50, 52 at approximately 45° to 47°. Anangle greater than 45° provides more spacing between the adjoined endsthan would be provided at 45° bevel cut. This allows for a greaterquantity of glue or adhesive 58 to be applied there between when an edgeis formed between pieces 50, 52. The bevel cuts may run the entirelength of the respective edges of two pieces of slab 44 to be adjoined.Respective bevel cuts may be made between pieces 50, 52 so that frontedge 52 extends upwardly from top surface 50 to form a perimeter or“seawall” around top surface 50 to prevent articles from unexpectedlysliding off top surface 50.

It has been determined that 47° bevel cuts provide a finished seambetween pieces 50, 52 of approximately 90° that is tightly adhered orbonded and the amount of adhesive adds strength to the structuralintegrity of the installed product. Making the bevel cut greater thanapproximately 47° may cause the glued joint to be too large when joiningtwo pieces to form a 90° seam. This may cause the edge formed betweentwo pieces, such as 50, 52 to not finish at a desired angle and thefinished product may not fit over countertop 14 in a desired manner.Bevel cuts of 47° or greater may be used when forming an obtuse anglebetween two pieces cut from slab 44.

When cutting pieces from slab 44, such as an edge band 53 shown in FIG.4A used for resurfacing existing edges of countertop 14 or pieces forresurfacing a back splash, the width of the cut for a piece may becalculated based on an inside dimension “ID” of a respective template 40for that piece plus the length “L” of the associated bevel cut as shownin FIG. 4A. This length “L” will vary based on the stone thickness.

Pieces cut from slab 44 may be kept flat and well supported during thefabrication process to help eliminate any warping or cracks from formingprior to and during installation. Some of the relatively thinner stoneswith affixed fiberglass backings have a tendency to warp or bow. Oncethis occurs the material will not easily return to its original shapeand forcing it may cause cracking. Natural stone is very hard and isalso quite brittle and will crack very easily. Suction cups may be usedto move material whenever possible to help prevent damage.

Pieces cut from slab 44 may be laid with their finished face down sothat any miter cuts, such as cuts 56, are facing up. The pieces may besupported so that the surfaces of the stone along the edged sides areaccessible and exposed for taping the pieces to be adjoined in closeproximity to each other. Blocks or other types of boards may be used asa form to support the pieces.

Once supported, the pieces may be prepared for being adjoined to buildedges that will fit over edges of existing structures such as theexisting edges of countertop 14. Pieces of slab 44 for covering edges ofcountertop 14, such as edge bands 53, may be cut to length. If an edgeband 53 is coming together with another edge band 53, such as in thecase of an inside or outside corner, an appropriate miter cut on eachedge band 53 may be made to ensure a fit and finish within acceptableranges of tolerance.

For example, referring to FIG. 5, piece 52 may be cut from slab 44 tocover a front edge of countertop 14 and may be laid flat with itsbeveled edge portion laying “point-to-point” with an opposing bevelededge portion of piece 50 cut for the top surface 17 of countertop 14.The material forming these pieces may be sufficiently dried prior toadjoining the pieces to ensure a good bond. An appropriate adhesivematerial 64 such as a 7-mil, 2″ clear vinyl tape may be used to hold thetwo pieces 50, 52 together as if to create a hinge there between. Thisallows for pieces 50, 52 to be maintained in the same relative positionwith respect to one another when being adjoined.

The adhesive or tape 64 is strong enough to hold pieces 50, 52 togetherwhile being sufficiently elastic so that when pieces 50, 52 are “folded”toward one another to form a 90° angle not too much of adhesive 58 issqueezed or forced out of the joint formed there between. The clarity oftape 64 allows the fabricator to see whether or not the joint will betight enough once pieces 50, 52 are glued together. Tape 64 may span thefull length of the joint for strength as well as to prevent the adhesivefrom flowing out onto a finished surface of pieces 50, 52.

Acetone may be used to remove dirt and dust particles from the bevel cutsurfaces prior to gluing pieces 50, 52 together. Acetone is beneficialbecause it will clean the glue joint and dry almost immediately forquickly proceeding to a step of gluing. If the joint is not clean anddry adhesive 58 may not bond properly. Glue or adhesive 58 may be atwo-part adhesive or glue that may be used mixed with the propercoloration to blend with the stone from which pieces 50, 52 are cut. Thetwo parts may be mixed and adhesive 58 spread in the joint 65 formed bythe beveled edges of pieces 50, 52 best shown in FIG. 5. In one aspect,joint 65 is covered as much as possible by applying adhesive 58 so it isflush with the surfaces 67 of pieces 50, 52. Any voids or air pocketsformed in adhesive 58 during application should be minimized oreliminated.

As shown in FIG. 6, after applying adhesive 58 pieces 50, 52 may be“folded” together to create an approximately 90° angle there between,which may be checked using a square. This angle forms an outer edge thatmay fit over an existing edge of countertop 14 when the finished productis installed. A piece of 2″ wide waterproof masking tape 66 may be usedto hold pieces 50, 52 together. Masking tape 66 is preferred over othermeans of adhering to avoid damage to the stone making pieces 50, 52.Clamp or clamping devices may result in edge or surface cracks in pieces50, 52 causing them to be wasted.

After pieces 50, 52 are folded into place there may be excess glue 58 onthe inside of the joint 65. The excess may be screed out of the insideof joint 65 so it will not harden and prevent the finished product fromfitting properly at installation. Glue 58 may have a defined workingtime and no more glue than what can be applied during the allottedworking time should be mixed in order to prevent waste or prematurehardening.

An appropriately sized block 68 having a chamfered corner may betemporarily placed on the inside of joint 65 to ensure the proper angleis achieved while glue 58 is drying. Block or blocks 68 may be held inplace with tape 66. Once glue 58 has cured or become substantially setblock 68 and masking tape 66 may be removed with vinyl tape 64 remainingin place to provide protection during a polishing step. Drying times ofglue 58 will vary depending on the type, brand, temperature and climateprevailing during gluing.

Referring to FIG. 7, one aspect allows for reinforcing an inside edgeformed by pieces 50, 52 proximate joint 65 using an adhesive material 70such as a 1½″-6 oz. fiberglass cloth 70, for example. Alternatematerials may be used to achieve this reinforcement. Material 70 may belaid along all or part of the inside edge to cover joint 65 created whenpieces 50, 52 are glued together. Other means may be used to reinforcejoint 65 to strengthen the structural relationship between pieces 50,52. Once material 70 is applied it may be coated with a liquid mixturesuch as a polyester resin mixed with a sanding aid and MEK-P catalyst.This three part liquid resin will absorb and harden the fiberglass clothto create an extremely strong, corrugated fiberglass reinforcement.

Applying material 70 covered with liquid resin helps to ensure thatjoints formed between various pieces of stone, such as 50, 52 do notfail or crack during or after installation. Material 70 and liquid resinmy be applied to some or all inside horizontal or vertical edge joints.Material 70 and liquid resin should preferably form a relatively smoothsurface against the inside surfaces of stone or otherwise the new stonetop may not fit properly over countertop 14. Any excess material 70 orliquid resin may be sanded down after it has set.

Aspects of the invention may be used to create a wide range ofstructures such as those used to resurface existing countertops 14 andback splashes 30 in a home with natural stone such as granite. It willbe appreciated that aspects of the invention may be used to form thesestructures in a manner so that the granite fits over top of the existingstructure being resurfaced. For example, a replacement countertop ofgranite may be formed to fit over existing countertop 14. To help ensurea proper fit, templates 40 may be placed inside of each respectivestructure formed with a template 40 prior to the structure'sinstallation. Template 40 should fit inside the respective structure andallow a fabricator to compare the dimensions of template 40 with thestructure. If template 40 does not fit inside the new structure withinallowable tolerances then the structure may be adjusted or remade, ifnecessary. All inside dimensions of the structure may be verified tomake sure they are what a respective template 40 requires.

Once all structures have been fitted to a respective template 40 thenthe edges of each structure may be polished. Polishing may be performedusing a series of nine diamond pads attached to a polishing machine, forexample, where each subsequent pad has finer level grit. The polishingstep may be a wet process. In one aspect, the seam formed at outer edge74 where the approximately 47° bevels of pieces 50, 52 have been gluedtogether and the very bottom of the edge 72 as shown in FIG. 8 may bepolished. The top or outer edge 74 may be polished to a ¼″ radius inorder to give the edge a softer look and feel. Any back splashes 30 maybe polished in a similar manner. Once all the top edges 74 have beenpolished the new seam should be inspected for any voids or air pocketsin the glue 58. If any voids are found they may be filled using the sameadhesive 58 that was used for bonding joint 65.

Structures or “tops”, such as a replacement countertop formed of granitethat will fit over countertop 14, may be prepared for any cutouts, suchas those needed for cook tops, sinks, under mount sinks, outlet holes inback splash 30, etc. With the exception of under mount sinks it ispreferable that all other cutouts be done in the field. Notwithstandingthe reinforcement of the replacement tops with material 70 and liquidresin they are still vulnerable to cracking and should be handled withcare. Keeping the new replacement tops straight and supported, usingsuction cups whenever possible, will help to ensure a damage freeproduct.

Aspects of the invention allow for extending existing surfaces such ascountertop 14, for instance. This may be accomplished by extending arespective template 40 to a desired dimension and fabricating thereplacement top to include the extended dimension. Since existingcountertop 14 has not changed in size a substrate of the same thicknessas the existing countertop 14 may be constructed to support the extendedportion of the new top. At the time of installation an adhesive may beapplied near the edge of existing countertop 14 and the substrate tobond this new internal seam together.

Another aspect of the invention allows for fabricating an edge, such aspiece 52 in a replacement top that has a radius of curvature thatmatches a radius of curvature in a top surface such as piece 50. Thisallows for fabricating replacement tops of granite having acircumferential or curvilinear edge extending downward there from thatmay fit over surfaces having nonlinear edges such as an oval counter ortable top with rounded ends, for example. In this aspect, a respectivetemplate 40 may be formed to represent the shape of a top surface 17having a radius of curvature for which a replacement top is to befabricated. Template 40 may be used to trace the surface and radius ofcurvature(s) onto slab 44. The radius may then be cut from slab 44 usinga common die grinder with a 4″ continuous rim blade, for example.

An approximately 47° bevel, such as those cut in pieces 50, 52 shown inFIG. 5, may be cut along the radius of curvature on the underside of thegranite piece cut from slab 44, using the same tool. A piece of backingsuch as a 1″ piece of Styrofoam or other suitable material may be usedto make a form having a radius of curvature patterned the same as theshort point of the radius of curvature on the backside or underside ofthe granite piece. The Styrofoam may be affixed to the underside of thegranite top using a hot glue gun so that the radius of curvature of theStyrofoam substantially aligns with and is setback from the radius ofcurvature defined by the granite top.

This allows for the Styrofoam form or template to be used as a temporarysubstrate or backing when adjoining an edge to the granite top. Theinventor of the present invention has found that it is impossible tobend a granite edge band 53 having a thickness of between about 5millimeters and 2 centimeters into a sufficiently tight radius ofcurvature to fit around a curved end of a standard tabletop, forexample, or to form other desired radiuses without breakage or damage.Consequently, in one aspect of the invention, an edge band 53 may besegmented by cutting it into individual mitered pieces as shown in FIG.9.

FIG. 9 illustrates a segmented radius edge 80 that may comprise aplurality of individual mitered pieces 82. Pieces 82 may be cut at awidth of not greater than about ¾″ to 1″ each with each piece 82 beingof approximately equal width. An upper edge 83 of each piece 82 may havea miter or bevel cut of approximately 45°-47° to mate with a similarlysized bevel cut in the underside of the granite top's edge to whichpieces 82 may be adjoined. The lateral edges or sides of each piece 82may have a miter or bevel cut along their length for mating and beingbonded with an adjacent piece 82. Segmented radius edge 80 may be bondedat each end with respective edge segments 84.

The angle of the bevel cuts may vary depending on the dimension of aradius of curvature being formed and in an embodiment the bevel cuts areapproximately 10°. Making bevel cuts in the lateral edges of eachadjacent piece 82 allows for those pieces 82 to conform to the shape ofthe radius of curvature when adjoined while forming an outer surfacethat is substantially smooth. The lateral edges of a piece 82 may havebevel cuts in opposing directions to form curvilinear shapes such as an“S”, for example.

A piece of vinyl tape, such as tape 64 may be used to tape all thepieces 82 together in a vertically orientated, adjacent manner with therespective mitered edges abutting each other. Vinyl tape 64 is strongenough to hold pieces 82 together and flexible enough to simultaneouslybend around the radius. The bevel on the underside of the granite topmay be aligned with the bevels on the upper edges 83 of the segmentedpieces 82 and pieces 82 may rest against the Styrofoam form. This allowsfor proper alignment and fit of pieces 82 to be checked withinacceptable tolerances.

After verifying a proper fit will be obtained, glue or adhesive 58described herein may be used to bond pieces 82 together and to theunderside of the granite top at the mating beveled cuts. Glue 58 may bespread on the respective bevel cuts in the underside of the granite topand the upper edges 83 of each piece 82, and in each individual mitercut along the sides of pieces 82. The taped pieces 82 may then bewrapped around the Styrofoam form and secured to the Styrofoam form andgranite top with more vinyl tape 64.

Once glue 58 has hardened the Styrofoam substrate may be removed byusing a utility knife, razor scraper and an 80-grit disc sander, forexample. Once the Styrofoam substrate is removed the inside edge formedbetween the segmented radius edge 80 and the granite top may bereinforced using material 70 and liquid resin as described herein. Tape64 may then be removed and the outer edge seam may be polished. Thepolishing process may be the same as described above with a finishedradius of approximately ¼″ on the top outer edge. The vertical surfaceof finished segmented radius edge 80 may be polished to ensure pieces 82blend together to seemingly form one piece.

Installation of the finished natural stone structures leaves a lastingimpression on the consumer. The quality of the installation also affectsthe overall strength and durability of the new structures.

An existing surface or structure to be resurfaced, such as countertop 14may be prepared for installation of the new top. A straight edge may belaid across countertop 14 to find any high or low spots. The surface ofcountertop 14 should be substantially flat for installation of the newtop. Any high or low spots should be addressed prior to the new topsbeing installed. Low spots may be circled with a permanent marker andfilled or built up by applying extra adhesive in those areas. Moresevere low areas may require loosening countertop 14 from its underlyingsupport structure, such as a cabinet and installing shims betweencountertop 14 and the support structure. High spots may be sanded downor even ground down in the case of harder surfaces such as ceramic tile.Regardless of the type of existing countertop 14, ceramic tile,laminate, solid surface, butcher block, etc. the surface should becompletely or substantially flat to avoid cracking or breaking of thenew top once installed.

An inside edge of a granite top or other structures formed in accordancewith aspects of the invention, such as one formed between pieces 50, 52may have a slight radius due to application of material 70 and liquidresin. In most cases, an existing countertop 14 will have square edges.These square edges may be cut with a bevel or chamfer to receive theradius of the new top's inside edge. This may be accomplished bysanding, grinding or in the case of laminate countertops using a trimrouter with a beveling bit.

The majority of existing countertops 14 have a smooth surface texture,which is not conducive to adhesion or bonding with a replacement top. Inorder to maximize the adhesion, a countertop's 14 surface may be treatedto form a rough surface texture to which a glue or adhesive can bond areplacement granite top. This may be accomplished with a low grit sandpaper, for example. In one aspect, a minimum of about 90% of thecountertop's 14 surface may be textured or roughed to ensure properbonding. Once the surface has been roughed it may be thoroughly cleanedand made substantially dust-free such as by using Acetone.

It will be recognized that there are generally two types of sinks:surface mount and under mount, being used by way. An under mount sink,such as one used in a household kitchen, is a sink mounted underneath acountertop surface thereby eliminating any exposure of the sink's rimabove the countertop surface. A surface mount sink has the rimoverlapping a portion of the countertop surface.

Before installing it may be necessary to cutout a portion of the topwith respect to a sink. With a sink existing within countertop 14, arespective template 40 may be laid on the existing countertop 14 and theexisting opening for the sink templated. The templated opening may betransferred onto the replacement granite top and the opening may becutout such as by using a die grinder with a 4″ diamond blade. Once thesink area is cutout an unfinished edge of the replacement granite top isexposed, which may be polished as described above.

An under mount sink may be installed by cutting a hole in the existingcountertop 14 slightly larger, approximately ¼″ on all sides, than theoverall sink dimensions. Referring to FIG. 10, a piece of plywood orother suitable material may be attached as a cleat 90 to the undersideof countertop 14 at one or more locations. Cleat 90 may be built up withshim 92 so that when in place an under mount sink 94 sets flush with thetop surface of existing countertop 14. The size of shim 92 or build upmay be determined by the thickness of the under mount sink rim 96.Alternate embodiments may use brackets (not shown) to affix under mountsink 94 to countertop 14 so its rim 96 is flush with countertop 14 asshown in FIG. 10. The approximate ¼″ reveal or spacing cut on all sidesof the existing countertop 14 allows for the sink 94 to be adjustedlaterally when in place beneath the new top 98.

Other openings for fitting the replacement granite top 98 in place maybe marked and cutout such as those for a cook top or outlet holes inback splash 30. Any replacement granite structure, such as replacementcountertop 98 may be dry-fit to verify that all edges fit tightlyagainst the existing structure being resurfaced such as existingcountertop 14. Dry fitting also allows for verifying that the bottom ofany new edge will be flush with or extend slightly below the bottom ofany existing structure edges. If all replacement granite structures fitproperly they may be glued in place.

Adhesives may be used to bond the replacement granite structure 98 to arespective substrate such as existing countertop 14. Three exemplarytypes of adhesive that may be used are: Lord 7545AB, which is a rapidset Urethane adhesive, Acrylic tile adhesive, which is a slower bondingadhesive and Laticrete 310R a rapid setting epoxy that may be usedparticularly for vertical applications in excess of about 6″. Using acombination of a rapid set adhesive with a slower bonding one allows forthe installer to make adjustments to the replacement top to ensure aproper fit.

The Acrylic adhesive may be spread using a ¼″×⅜″×¼″ grooved trowel overthe surface of countertop 14, so that a minimum of approximately 90% ofthe surface area is covered. Approximately ½″ of clean surface may beleft around all edge and opening perimeters for applying the 7545ABadhesive. Additional adhesive may be added where needed in low areasthat may have been marked previously or identified during application ofthe adhesive. The 7545AB may be applied using a gun provided by themanufacturer, for example. An approximately ¼″ continuous bead may beapplied around all edge perimeters and the perimeter edges of anyopenings.

Replacement granite structure 98 may be positioned onto the existingstructure or substrate, such as countertop 14 while minimizing slidingof the structure 98 across the surface of countertop 14, which maydisturb the adhesive. Once the replacement granite top 98 is set inplace it may be pressed down on firmly working from the center out toobtain a good fit.

The replacement granite top 98 may be clamped where necessary usingpinch clamps, for example. Clamping does not require excessive pressure.If too much pressure is required then there may be a problem in thepreparation of the countertop 14 surface. In this case, replacementgranite top 98 may be removed, the adhesive cleaned off, replacementgranite top 98 refit and the process repeated. The 7545AB only has aworking time of about 5-7 minutes at 72° F. so it is important that oncethe adhesive is applied replacement granite top 98 is immediatelyinstalled. Silicone may be used where granite meets granite and caulkingwhere granite meets any other surface. There are several siliconescommercially available just for granite applications. The installed top98 may be cleaned using a natural stone cleaner.

While the exemplary embodiments of the present invention have been shownand described by way of example only, numerous variations, changes andsubstitutions will occur to those of skill in the art without departingfrom the invention herein. Accordingly, it is intended that theinvention be limited only by the spirit and scope of the appendedclaims.

1) A method of resurfacing a substrate having a surface and an edge, themethod comprising: placing at least one templating strip on thesubstrate surface to form a template defining an outside dimension ofthe substrate surface; removing the template from the substrate surface;overlaying the template on a sheet of resurfacing material; determiningan amount of overhang for a substrate surface replacement piece toextend beyond the outside dimension of the substrate surface; cuttingthe substrate surface replacement piece from the sheet of resurfacingmaterial based on the outside dimension of the template and thedetermined amount of overhang, the substrate surface replacement pieceused for resurfacing the substrate surface; cutting an edge band fromthe sheet of resurfacing material for resurfacing the edge of thesubstrate, the edge band having a thickness that is substantially thesame as the determined amount of overhang; bonding the edge band and thesubstrate surface replacement piece together to form a replacementstructure; and adhesively joining the replacement structure to thesubstrate. 2) The method of claim 1 further comprising: the resurfacingmaterial comprising a natural stone; and cutting the substrate surfacereplacement piece and the edge band from a slab of the natural stonehaving a thickness of about 5 millimeters to 19 millimeters. 3) Themethod of claim 2, the bonding step comprising: cutting a bevel of about45° to 47° along a length of the outside dimension of the substratesurface replacement piece; cutting a bevel of about 45° to 47° along alength of the edge band; laying the substrate surface replacement pieceand the edge band on a piece of adhesive material so their respectivebevel cuts are parallel and adjacent; applying an adhesive to arespective surface of each bevel cut; and forming an approximately 90°angle between the substrate surface replacement piece and the edge bandto form an inside edge. 4) The method of claim 3, the bonding stepfurther comprising: positioning a block in the inside edge against whichthe substrate surface replacement piece and the edge band may each bebraced; and compressing the edge band toward the substrate surfacereplacement piece to maintain the approximately 90° angle there between.5) The method of claim 3 further comprising: applying a reinforcingfiberglass cloth along the inside edge; and applying a liquid resin overthe reinforcing fiberglass cloth. 6) The method of claim 1 furthercomprising: cutting the substrate surface replacement piece to include afirst radius of curvature portion; and bonding the edge band to thesubstrate surface replacement piece so the edge band is aligned with thefirst radius of curvature portion when the replacement structure isadhesively joined to the substrate. 7) The method of claim 1 furthercomprising wherein the determined amount of overhang is greater than amaximum thickness of the edge band. 8) The method of claim 7 further:leveling a top surface of the substrate; and adhesively joining thesubstrate surface replacement piece to the top surface using a firstadhesive having a first setting time and a second adhesive having asecond setting time where the first setting time is longer than thesecond setting time. 9) A method of resurfacing a substrate with aresurfacing material the method comprising: placing a plurality oftemplating strips on a top surface of the substrate to form a templatesized to cut a first piece of the resurfacing material for resurfacingthe top surface of the substrate; removing the template from the topsurface of the substrate; overlaying the template on the resurfacingmaterial; cutting the first piece of the resurfacing material based onan outside dimension of the template; cutting an edge band of theresurfacing material sized to resurface an edge of the substrate;cutting a bevel in an edge along a length of the first piece of theresurfacing material; cutting a bevel in an edge along a length of theedge band of the resurfacing material; adjoining the first piece of theresurfacing material and the edge band of the resurfacing material toform a replacement piece, the first piece of the resurfacing materialand the edge band of the resurfacing material adjoined along theirrespective beveled edges to form a substantially right angle therebetween having an inside edge; applying a fiberglass cloth to the insideedge; and adhesively joining the replacement piece to the top surfaceand the edge of the substrate. 10) The method of claim 9 furthercomprising: placing the plurality of templating strips on the topsurface of the substrate so the outside dimension of the template issubstantially the same as an outside dimension of the top surface of thesubstrate; determining an amount of overhang the first piece of theresurfacing material will extend beyond the edge of the substrate; andcutting the first piece of the resurfacing material based on the outsidedimension of the template plus the determined amount of overhang. 11)The method of claim 10 wherein the determined amount of overhang isgreater than a thickness of the edge band of the resurfacing material.12) The method of claim 9 further comprising: cutting a plurality ofresurfacing material pieces of substantially the same dimensions, eachpiece comprising a respective top edge and respective lateral edges;cutting a radius of curvature along an edge of the first piece of theresurfacing material; cutting a bevel of approximately 10° in therespective lateral edges of the plurality of resurfacing materialpieces; cutting a bevel of approximately 45° to 47° in the respectivetop edges of the plurality of resurfacing material pieces; cutting abevel of approximately 45° to 47° in the edge of the first piece of theresurfacing material having the radius of curvature; adjoining theplurality of resurfacing material pieces along their respective lateraledges to form a segmented radius of curvature; and adjoining thesegmented radius of curvature to the edge of the first piece of theresurfacing material having the radius of curvature. 13) A method ofresurfacing a substrate with a natural stone having a thickness of about5 millimeters to 19 millimeters, the substrate comprising a top surfaceand an edge extending downwardly from at least a portion of the topsurface, the method comprising: cutting a top piece of the natural stonesized to cover at least a portion of the substrate's top surface anddefining an edge having a radius of curvature overhanging acorresponding radius of curvature of the substrate's edge; cutting aplurality of natural stone pieces of substantially the same dimensions,each piece comprising a respective top edge and respective lateraledges; cutting a bevel in the respective lateral edges of the pluralityof natural stone pieces; adjoining the plurality of natural stone piecesalong their respective lateral edges to form a segmented radius ofcurvature; adjoining the segmented radius of curvature to the radius ofcurvature of the top piece to form a replacement top; and adhering thereplacement top to the substrate so that the segmented radius ofcurvature covers the radius of curvature of the substrate's edge. 14)The method of claim 13 further comprising: cutting a bevel in the edgeof the top piece having the radius of curvature; cutting a bevel in therespective top edges of the plurality of natural stone pieces; andadjoining the segmented radius of curvature to the radius of curvatureof the top piece along their respective beveled edges. 15) The method ofclaim 13 further comprising: cutting the top piece to define a linearedge overhanging a corresponding linear portion of the substrate's edge;cutting an edge band of the natural stone sized to cover a surface ofthe corresponding linear portion of the substrate's edge; cutting abevel in the linear edge of the top piece; cutting a bevel in an edge ofthe edge band; adjoining the top piece and the edge band along theirrespective beveled edges to form the replacement top; and adhering thereplacement top to the substrate so that the segmented radius ofcurvature covers the radius of curvature of the substrate's edge and theedge band covers the linear portion of the substrate's edge. 16) Amethod of fabricating and installing a structure on an existingsubstrate, the method comprising: providing a sheet of resurfacingmaterial; cutting a first piece from the sheet of resurfacing materialfor resurfacing a surface of the existing substrate, the first piece ofthe resurfacing material sized to include an expansion gap that willoverhang an edge of the existing substrate when the first piece of theresurfacing material is placed over the surface of the existingsubstrate; cutting a second piece from the sheet of resurfacing materialfor resurfacing the edge of the existing substrate, the second piece ofthe resurfacing material having a thickness that is less than a width ofthe expansion gap; adhesively joining the first piece of the resurfacingmaterial and the second piece of the resurfacing material to form thestructure; and adhesively joining the structure to the surface of theexisting substrate. 17) The method of claim 16 further comprising:sizing the expansion gap to be greater than a maximum thickness of thesecond piece of the resurfacing material. 18) The method of claim 16further comprising: placing a plurality of templating strips on thesurface of the existing substrate to form a template having an outsidedimension that is substantially the same as an outside dimension of thesurface of the existing substrate; removing the template from thesurface of the existing substrate; overlaying the template on the sheetof resurfacing material; sizing the expansion gap to be greater than amaximum thickness of the second piece of the resurfacing material; andcutting the first piece of resurfacing material based on the outsidedimension of the template and the size of the expansion gap.